Methods and Apparatus for Dispensing Solid Pharmaceutical Articles

ABSTRACT

An apparatus for dispensing pharmaceutical articles includes a housing and a gas source to provide a positive pressure supply gas flow. The housing defines a hopper chamber to hold the articles, a dispensing channel fluidly connected to the hopper chamber, a drive jet outlet, and an agitation outlet. The dispensing channel has an inlet and an outlet and defines a flow path therebetween. The gas source is fluidly connected to each of the drive jet outlet and the agitation outlet to provide: a pressurized drive jet gas flow through the drive jet outlet to convey articles through the dispensing channel along the flow path; and a pressurized agitation gas flow through the agitation outlet to agitate articles in the hopper chamber.

RELATED APPLICATION(S)

The present application is a continuation patent application of andclaims priority from U.S. patent application Ser. No. 11/750,710, filedMay 18, 2007, the disclosure of which is hereby incorporated herein byreference in its entirety.

FIELD OF THE INVENTION

The present invention is directed generally to the dispensing of solidpharmaceutical articles and, more specifically, is directed to theautomated dispensing of solid pharmaceutical articles.

BACKGROUND OF THE INVENTION

Pharmacy generally began with the compounding of medicines whichentailed the actual mixing and preparing of medications. Heretofore,pharmacy has been, to a great extent, a profession of dispensing, thatis, the pouring, counting, and labeling of a prescription, andsubsequently transferring the dispensed medication to the patient.Because of the repetitiveness of many of the pharmacist's tasks,automation of these tasks has been desirable.

Some attempts have been made to automate the pharmacy environment.Different exemplary approaches are shown in U.S. Pat. No. 5,337,919 toSpaulding et al. and U.S. Pat. Nos. 6,006,946; 6,036,812 and 6,176,392to Williams et al. These systems utilize robotic arms to grasp acontainer, carry it to one of a number of bins containing tablets (fromwhich a designated number of tablets are dispensed), carry it to aprinter, where a prescription label is applied, and release the filledcontainer in a desired location. Tablets are counted and dispensed withany number of counting devices. Drawbacks to these systems typicallyinclude the relatively low speed at which prescriptions are filled andthe absence in these systems of securing a closure (i.e., a lid) on thecontainer after it is filled.

One automated system for dispensing pharmaceuticals is described in somedetail in U.S. Pat. No. 6,971,541 to Williams et al. This system has thecapacity to select an appropriate vial, label the vial, fill the vialwith a desired quantity of a selected pharmaceutical tablet, apply a capto the filled vial, and convey the labeled, filled, capped vial to anoffloading station for retrieval. Although this particular system canprovide automated pharmaceutical dispensing, it may be desirable tomodify certain aspects of the system to address particular needs.

SUMMARY OF THE INVENTION

According to embodiments of the present invention, an apparatus fordispensing pharmaceutical articles includes a housing and a gas sourceto provide a positive pressure supply gas flow. The housing defines ahopper chamber to hold the articles, a dispensing channel fluidlyconnected to the hopper chamber, a drive jet outlet, and an agitationoutlet. The dispensing channel has an inlet and an outlet and defines aflow path therebetween. The gas source is fluidly connected to each ofthe drive jet outlet and the agitation outlet to provide: a pressurizeddrive jet gas flow through the drive jet outlet to convey articlesthrough the dispensing channel along the flow path; and a pressurizedagitation gas flow through the agitation outlet to agitate articles inthe hopper chamber.

According to some embodiments, the agitation gas flow has a greater massflow rate than the drive jet gas flow. According to some embodiments,the agitation gas flow has a greater mass flow rate than the supply gasflow. According to some embodiments, an air amplifier is interposed andfluidly connected between the gas source and the agitation outlet. Theair amplifier may be configured to utilize the Coanda Effect.

According to method embodiments of the present invention, a method isprovided for dispensing pharmaceutical articles using an apparatusincluding a housing defining a hopper chamber to hold the articles, adispensing channel fluidly connected to the hopper chamber, a drive jetoutlet, and an agitation outlet, the dispensing channel having an inletand an outlet and defining a flow path therebetween, the apparatusfurther including a gas source fluidly connected to each of the drivejet outlet and the agitation outlet. The method includes providing apositive pressure supply gas flow from the gas source to each of thedrive jet outlet and the agitation outlet to generate each of apressurized drive jet gas flow through the drive jet outlet and apressurized agitation gas flow through the agitation outlet. The drivejet gas flow conveys articles through the dispensing channel along theflow path and the agitation gas flow agitates articles in the hopperchamber.

According to some embodiments, the agitation gas flow has a greater massflow rate than the drive jet gas flow. According to some embodiments,the agitation gas flow has a greater mass flow rate than the supply gasflow. According to some embodiments, the supply gas flow is providedfrom the gas source to the agitation outlet via an air amplifierinterposed and fluidly connected between the gas source and theagitation outlet. The air amplifier may be configured to utilize theCoanda Effect.

According to further embodiments of the present invention, an apparatusfor dispensing pharmaceutical articles includes a dispensing channelhaving an inlet and an outlet and defining a flow path therebetween, anda housing defining a hopper chamber to hold the articles. The hopperchamber is in fluid communication with the inlet of the dispensingchannel. The housing includes a floor and a divider wall configured todefine, in the hopper chamber: a front region between the inlet and thedivider wall; a rear region on a side of the divider wall opposite thefront region; and a choke passage between the front and rear regions andbetween the divider wall and the floor. According to some embodiments, aspacing between the divider wall and the floor is adjustable to adjustthe size of the choke passage.

Further features, advantages and details of the present invention willbe appreciated by those of ordinary skill in the art from a reading ofthe figures and the detailed description of the preferred embodimentsthat follow, such description being merely illustrative of the presentinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart illustrating methods according to embodiments ofthe present invention.

FIG. 2 is a perspective view of a pharmaceutical tablet dispensingsystem including a sensor clearing system according to embodiments ofthe present invention.

FIG. 3 is a cutaway view of the tablet dispensing system of FIG. 2illustrating a container dispensing station, a labeling carrier, adispensing carrier, and a closure dispensing station thereof.

FIG. 4 is a top, front perspective view of a dispensing bin according toembodiments of the present invention.

FIG. 5 is a bottom perspective view of the bin of FIG. 4.

FIG. 6 is a cross-sectional, perspective view of the bin of FIG. 4.

FIG. 7 is a cross-sectional view of the bin of FIG. 4.

FIG. 8 is a cross-sectional view of the bin of FIG. 4 wherein tabletscontained therein are at rest.

FIG. 9 is a cross-sectional view of the bin of FIG. 4 wherein tabletscontained therein are being agitated and dispensed.

FIG. 10 is a cross-sectional view of the bin of FIG. 4 wherein tabletscontained therein are being agitated and returned to a hopper chamber ofthe bin.

FIG. 11 is an enlarged, exploded, top perspective view of an airamplifier of the bin of FIG. 4.

FIG. 12 is a cross-sectional view of the air amplifier of FIG. 10.

FIG. 13 is a block diagram representing gas supply flow paths of the binof FIG. 4.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which illustrativeembodiments of the invention are shown. In the drawings, the relativesizes of regions or features may be exaggerated for clarity. Thisinvention may, however, be embodied in many different forms and shouldnot be construed as limited to the embodiments set forth herein; rather,these embodiments are provided so that this disclosure will be thoroughand complete, and will fully convey the scope of the invention to thoseskilled in the art.

It will be understood that when an element is referred to as being“coupled” or “connected” to another element, it can be directly coupledor connected to the other element or intervening elements may also bepresent. In contrast, when an element is referred to as being “directlycoupled” or “directly connected” to another element, there are nointervening elements present. Like numbers refer to like elementsthroughout.

In addition, spatially relative terms, such as “under”, “below”,“lower”, “over”, “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. It will beunderstood that the spatially relative terms are intended to encompassdifferent orientations of the device in use or operation in addition tothe orientation depicted in the figures. For example, if the device inthe figures is turned over, elements described as “under” or “beneath”other elements or features would then be oriented “over” the otherelements or features. Thus, the exemplary term “under” can encompassboth an orientation of over and under. The device may be otherwiseoriented (rotated 90 degrees or at other orientations) and the spatiallyrelative descriptors used herein interpreted accordingly.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises”and/or “comprising,” when used in this specification, specify thepresence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, elements,components, and/or groups thereof. As used herein the expression“and/or” includes any and all combinations of one or more of theassociated listed items.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this invention belongs. It will befurther understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the relevant art andwill not be interpreted in an idealized or overly formal sense unlessexpressly so defined herein.

In accordance with embodiments of the present invention, apparatus andmethods are provided for dispensing solid pharmaceutical articles. Inparticular, such methods and apparatus may be used to dispensepharmaceuticals. With reference to FIG. 1, methods according toembodiments of the present invention may be executed using an apparatusincluding a housing defining a hopper chamber to hold the articles, adispensing channel fluidly connected to the hopper chamber, a drive jetoutlet, and an agitation outlet, the dispensing channel having an inletand an outlet and defining a flow path therebetween, the apparatusfurther including a gas source fluidly connected to each of the drivejet outlet and the agitation outlet. A positive pressure supply gas flowis provided from the gas source to each of the drive jet outlet and theagitation outlet to generate each of a pressurized drive jet gas flowthrough the drive jet outlet and a pressurized agitation gas flowthrough the agitation outlet such that the pressurized drive jet gasflow conveys articles through the dispensing channel along the flow pathand the pressurized agitation gas flow agitates articles in the hopperchamber (Block 20). According to some embodiments, the articles arepharmaceutical tablets or pills.

According to some embodiments, the agitation gas flow has a higher orgreater mass flow rate than the drive jet gas flow. According to someembodiments, the agitation gas flow has a greater mass flow rate thanthe supply gas flow. The supply gas flow may be provided from the gassource to the agitation outlet via an air amplifier interposed andfluidly connected between the gas source and the agitation outlet.According to some embodiments, the drive jet outlet and the agitationoutlet are supplied by the same gas source. According to someembodiments, the drive jet gas flow and the agitation gas flow areprovided simultaneously. The air amplifier may be configured to utilizethe Coanda Effect.

A dispensing system according to embodiments of the present inventionand that can carry out the foregoing methods is illustrated in FIGS.2-13 and designated broadly therein at 40 (FIGS. 2 and 3). The system 40includes a support frame 44 for the mounting of its various components.Those skilled in this art will recognize that the frame 44 illustratedherein is exemplary and can take many configurations that would besuitable for use with the present invention. The frame 44 provides astrong, rigid foundation to which other components can be attached atdesired locations, and other frame forms able to serve this purpose mayalso be acceptable for use with this invention.

The system 40 generally includes as operative stations a controller(represented herein by a graphics user interface 42), a containerdispensing station 58, a labeling station 60, a tablet dispensingstation 62, a closure dispensing station 64, and an offloading station66. In the illustrated embodiment, containers, tablets and closures aremoved between these stations with a dispensing carrier 70; however, insome embodiments, multiple carriers are employed. The dispensing carrier70 has the capability of moving the container to designated locationswithin the cavity 45 of the frame 44. Except as discussed herein withregard to the dispensing station 62, each of the operative stations andthe conveying devices may be of any suitable construction such as thosedescribed in detail in U.S. Pat. No. 6,971,541 to Williams et al. and/orU.S. Patent Publication No. US-2006-0241807-A1, the disclosures of whichare hereby incorporated herein in their entireties.

The controller 42 controls the operation of the remainder of the system40. In some embodiments, the controller 42 will be operatively connectedwith an external device, such as a personal or mainframe computer, thatprovides input information regarding prescriptions. In otherembodiments, the controller 42 may include a stand-alone computer thatdirectly receives manual input from a pharmacist or other operator. Anexemplary controller may include a conventional microprocessor-basedpersonal computer. The controller 42 may be a centralized computer orportions thereof may be physically and/or functionally distributed ordivided into multiple controllers. For example, according to someembodiments, the controller is embodied in part in each tabletdispensing bin assembly.

In operation, the controller 42 signals the container dispensing station58 that a container of a specified size is desired. In response, thecontainer dispensing station 58 delivers a container for retrieval bythe carrier 70. From the container dispensing station 58, the containeris moved to the labeling station 60 by the carrier 70. The labelingstation 60 includes a printer that is controlled by the controller 42.The printer prints and presents an adhesive label that is affixed to thecontainer.

Filling of labeled containers with tablets is carried out by the tabletdispensing station 62. The tablet dispensing station 62 comprises aplurality of tablet dispensing bin assemblies or bins 100 (described inmore detail below), each of which holds a bulk supply of individualtablets (typically the bins 100 will hold different tablets). Referringto FIGS. 2 and 4-7, the dispensing bins 100, which may be substantiallyidentical in size and configuration, are organized in an array mountedon the rails of the frame 44. Each dispensing bin 100 has a dispensingchannel 116 with an outlet 116B (FIG. 7) that faces generally in thesame direction, to create an access region for the dispensing carrier70. The identity of the tablets in each bin is known by the controller42, which can direct the dispensing carrier 70 to transport thecontainer to the proper bin 100.

The dispensing bins 100 are configured to singulate, count, and dispensethe tablets contained therein, with the operation of the bins 100 andthe counting of the tablets being controlled by the controller 42.According to some embodiments, each bin 100 includes its own dedicatedcontroller that is operative to execute a dispensing run upon receivinga command from a central controller or the like. Some embodiments mayemploy the controller 42 as the device which monitors the locations andcontents of the bins 100; others may employ the controller 42 to monitorthe locations of the bins, with the bins 100 including indicia (such asa bar code or electronic transmitter) to identify the contents to thecontroller 42. In still other embodiments, the bins 100 may generate andprovide location and content information to a central controller, withthe result that the bins 100 may be moved to different positions on theframe 44 without the need for manual modification of the centralcontroller (i.e., the bins 100 will update the central controllerautomatically).

Any of a number of dispensing units that singulate and count discreteobjects may be employed if suitably modified to include the inventiveaspects disclosed herein. In particular, dispensing units that rely upontargeted air flow and a singulating nozzle assembly may be used, such asthe devices described in U.S. Pat. No. 6,631,826 to Pollard et al.and/or U.S. Patent Publication No. US-2006-0241807-A1, each of which ishereby incorporated herein by reference in its entirety. Bins of thisvariety may also include additional features, such as those describedbelow.

After the container is desirably filled by the tablet dispensing station62, the dispensing carrier 70 moves the filled container to the closuredispensing station 64. The closure dispensing station 64 may house abulk supply of closures and dispense and secure them onto a filledcontainer. The dispensing carrier 70 then moves to the closed container,grasps it, and moves it to the offloading station 66.

Turning to the bins 100 in more detail, an exemplary bin 100 is shown inmore detail in FIGS. 4-13. The bin 100 includes a housing 110 having ahopper portion 112 and a nozzle 114. The bin 100 is fluidly connectedwith a pressurized gas source 136 as discussed in more detail below.

Referring to FIGS. 6-8, the hopper portion 112 defines a hopper chamber120 that can be filled with tablets T (FIG. 8). The bin 100 can befilled or replenished with tablets through an opening 130 located at theupper rear portion of the bin 100. The opening 130 is selectivelyaccessible via a pivoting door 132, for example.

The nozzle 114 defines the dispensing channel 116 through which thetablets T can be dispensed one at a time into the container C, forexample (FIGS. 9 and 10). The dispensing channel 116 has an inlet 116Aopposite the outlet 116B and fluidly connects the channel 116 to thechamber 120. As disclosed in U.S. Patent Publication No.US-2006-0241807-A1, the bin 100 may include components that permit theentry to the dispensing channel 116 to be adjusted in size to complementthe size and configuration of the tablet to be dispensed. For example,an upper wall 118 defining a portion of the dispensing passage 116 maybe slid able up and down to selectively adjust the height of the passage116 and/or the inlet 116A. A side wall may be similarly movable toadjust the width of the passage 116 and/or the inlet 116A.

With reference to FIG. 6, the hopper portion 112 has a bottom walldefining a floor 122. The floor 122 has a sloped rear portion 122A thatslopes downwardly toward the inlet 116A. The floor 122 also has afunnel-shaped front portion 122B. A front agitation port or outlet 122Cand a rear agitation port or outlet 122D are provided in the floor 122.As discussed below, air or other pressurized gas can be flowed throughthe outlets 122C, 122D and into the chamber 120 to agitate the tablets Tcontained therein.

With reference to FIG. 7, a front partition or divider wall 124 extendsthrough the hopper chamber 120 and forms a gap or choke point 124Abetween the lower edge of the wall 124 and the floor 122. According tosome embodiments, the choke point 124A has a gap spacing or height G1(FIG. 7) of between about 0.25 and 0.75 inch. The position of the wall124, and thereby the gap spacing G1, may be selectively adjusted usingan adjustment mechanism 124B (FIG. 4).

A rear partition or divider wall 126 extends through the hopper chamber120 and forms a gap or choke point 126A between the lower edge of thewall 126 and the floor 122. According to some embodiments, the chokepoint 126A has a gap spacing or height G2 (FIG. 7) of between about 0.6and 1 inch. The position of the wall 126, and thereby the gap spacingG2, may be selectively adjusted using an adjustment mechanism 126B (FIG.4). According to some embodiments, the rear divider wall 126 forms anangle A (FIG. 7) of at least about 30 degrees with respect to horizontaland, according to some embodiments, between about 30 and 45 degrees withrespect to horizontal.

The front divider wall 124 and rear divider wall 126 divide the hopperchamber 120 into subchambers or regions. More particularly and referringto FIG. 7, a front region or subchamber 120A is defined between thedivider wall 124 and the inlet 116A, an intermediate region orsubchamber 120B is defined between the front divider wall 124 and therear divider wall 126, and a rear region or subchamber 120C is definedbetween the rear divider wall 126 and the rear wall of the bin 100.

With reference to FIG. 8, the housing 110 further includes a highpressure supply port or nozzle 134. In use, the pressurized gas source136 is fluidly connected to the high pressure nozzle 134 via a manifold,fitting, flexible or rigid conduit 134A, or the like. The gas source 136may include a compressor or a container of compressed gas, for example.The high pressure gas source 136 is operative to provide a supply gasflow of a suitable working gas at a high pressure to the nozzle 134.According to some embodiments, the supplied gas is or includes air.According to some embodiments, the pressure of the supplied gas at thenozzle 134 is at least about 10 psi and, according to some embodiments,between about 10 and 60 psi. A flowpath network for the supplied gas isschematically illustrated in FIG. 13 and described below.

With reference to FIGS. 7, 9 and 13, a gas supply passage or conduit140A (FIG. 7) fluidly connects the high pressure nozzle 134 to a forwardcontrol valve 142. Two forward jet supply passages 140C (FIG. 9) fluidlyconnect the forward control valve 142 to respective forward drive jetapertures or outlets 146. The forward jet outlets 146 are positioned andconfigured to direct air or other supplied gas into the dispensingchannel 116. A front agitation supply passage 140E (FIG. 9) fluidlyconnects the forward control valve 142 to a front air amplifier 150. Thefront air amplifier 150 is positioned and configured to direct air orother supplied gas into the hopper chamber 120 through the frontagitation outlet 122C. The forward control valve 142 is operable tocontrol airflow to the forward jet outlets 146 and the front airamplifier 150.

With reference to FIGS. 7, 10 and 13, a gas supply passage or conduit140B (FIG. 7) fluidly connects the high pressure nozzle 134 to a reversecontrol valve 144. A reverse jet supply passage 140D (FIG. 10) fluidlyconnects the reverse control valve 144 to a reverse drive jet apertureor outlet 148. The reverse jet outlet 148 is positioned and configuredto direct air or other supplied gas into the dispensing channel 116. Arear agitation supply passage 140F (FIG. 10) fluidly connects thereverse control valve 144 to a rear air amplifier 160. The rear airamplifier 160 is positioned and configured to direct air or othersupplied gas into the hopper chamber 120 through the rear agitationoutlet 122D. The reverse control valve 144 is operable to controlairflow to the reverse jet outlet 148 and the rear air amplifier 160.

The gas supply passages 140A-F may be of any suitable construction andconfiguration. According to some embodiments, some or all of thepassages 140A-F are defined in whole or in part by channels formed inthe housing 110. These channels may be machined or molded into thehousing 110.

Each of the air amplifiers 150, 160 is secured to the housing 110. Theair amplifiers 150, 160 may be of any suitable construction to effectthe functionality described herein. According to some embodiments, theair amplifiers 150, 160 are constructed as described below with regardto the air amplifier 150. The air amplifiers 150, 160 may be constructedin the same or similar manners and it will therefore be appreciated thatthis description can likewise apply to the air amplifier 160 (and/or anyadditional air amplifiers).

With reference to FIGS. 11 and 12, the air amplifier 150 includes anouter body 152, an inner body 154 and a gasket or shim 153. Thecomponents 152, 153, 154 may be formed of any suitable material(s).According to some embodiments, the bodies 152, 154 are formed of a rigidpolymeric material, which, according to some embodiments, is molded. Theshim 153 may also be formed of a rigid polymeric material or, accordingto other embodiments, an elastomeric material. The bodies 152, 154 mayeach be unitarily formed as illustrated or may each comprise assembledsubcomponents. Moreover, the bodies 152, 154 may be unitarily formedtogether.

The outer body 152 includes an annular center wall 152A, an annularinner wall 152B, and an annular channel 152C defined therebetween. Afeed opening 152D is defined in the wall 152A and fluidly communicateswith the channel 152C. When the air amplifier 150 is installed in thehousing 110, the gas supply passage 140D (FIG. 7) is fluidly connectedto the feed opening 152D to supply the gas from the gas source 136 tothe channel 152C. Similarly, when the air amplifier 160 is installed inthe housing 110, the gas supply passage 140F is fluidly connected to thefeed opening of the air amplifier 160 to supply the gas from the gassource 136 to the annular channel of the air amplifier 160. The body 152defines a central passage 152E extending up through the wall 152B. Thebody 152 has a relatively sharp or squared, annular upper edge or cornersurface 152F defining a portion of the passage 152E. According to someembodiments, the side and bottom surfaces forming the edge 152F form anangle of about 90 degrees.

The inner body 154 has an upstanding projection or collar 154A. Acentral passage 154B extends through the inner body 154. The body 154has a relatively rounded or arcuate, annular lower edge or cornersurface 154C defining a portion of the passage 154B.

The components 152, 153, 154 are assembled as shown in FIG. 12 such thatthe shim 153 is interposed or sandwiched between the bodies 152, 154.The assembled air amplifier 150 has an inlet 156A, an interior chamber156B, a central passage 156C and an outlet 156D. The interior chamber156B includes the channel 152C.

In use and with reference to FIG. 12, the air amplifier 150 (andlikewise the air amplifier 160) can be used to convert a suppliedpressurized gas flow having a given pressure, velocity and mass flowrate into an exiting or output air flow having a comparatively lowerpressure, higher velocity, and higher mass flow rate. More particularly,the valve 142 can be opened to supply a flow FS of pressurized gas tothe channel 152C via the opening 152D. The supplied gas flows around thechannel 152C, into the chamber 156B, and into the central passage 156C(as indicated by the arrows FC). The gas flow FC responding to thejuxtaposition of the rounded surface 156C opposite and adjacent thesharp corner 152F generally and preferentially follows the roundedsurface 154C up through the passage 154B and out through the outlet 156Das a result of the Coanda effect. Due to the Coanda effect, a vacuum orlow pressure region is established on or adjacent to the surface 154C.This low pressure region draws a flow of ambient air FE through theinlet 156A. The flow FE is drawn up through the passage 156C and outthrough the outlet 156C. The two flows FC and FE thereby combine toprovide an exit gas flow FAF. The exit gas flow FAF has a pressure thatis less than the pressure of the supplied gas FS and a mass flow ratethat is greater than that of the supplied gas FS.

The outlet 156D of the air amplifier 150 is positioned in or adjacentthe agitation outlet 122C so that the exit gas flow FAF enters thehopper chamber 120 through the outlet 122C. Similarly, the correspondingoutlet of the air amplifier 160 is positioned in or adjacent theagitation outlet 122D so that an exit gas flow FAR exiting the airamplifier 160 enters the hopper chamber 120 through the outlet 122D(FIG. 10).

According to some embodiments and as illustrated, one or both of the airamplifiers 150, 160 are mounted on or integrated into the housing 110.The air amplifiers 150, 160 may be separately formed from the housing110 and secured to the housing by adhesive, fasteners, integralmechanical structures, or the like. All or a portion of each airamplifier 150, 160 may be integrally molded into the housing 110. Eachamplifier 150, 160 can be separately formed from the housing 110 andinsert molded into the housing 110.

One or more sensors 115 are operatively positioned in the dispensingchannel 116. According to some embodiments, the sensors 115 are countingsensors and are operably connected to associated sensorreceiver/processor electronics. As further discussed below, the sensors115 are configured and positioned to detect the tablets T as they passthrough the dispensing channel 116. According to some embodiments, thesensors 115 are photoelectric sensors. According to some embodiments, atleast one of the sensors includes a photoemitter and the other sensorincludes a photodetector that receives photoemissions from thephotoemitter of the first sensor.

A connector circuit board or other electrical connector may be mountedon the bin 100 to provide an electrical connection between an externalcontroller and a bin-controlling circuit board or other electroniccomponent of the bin 100 for power and data signals from the externalcontroller and the counting sensors 115.

Exemplary operation of the dispensing system 40 will now be described.The bin 100 is filled with tablets T to be dispensed. The tablets T mayinitially be at rest as shown in FIG. 8. At this time, the valves 142,144 are closed so that no gas flow is provided through the jet outlets146, 148 or the agitation outlets 122C, 122D.

When is it desired to dispense the tablets T to fill the container C,the dispensing carrier 70, directed by the controller 42, moves thecontainer C to the exit port 116B of the selected dispensing bin 100.The controller 42 signals the forward valve 142 to open (while therearward valve 144 remains closed). The opened valve 142 permits thepressurized gas from the gas source 136 to flow through the passages140C and out through the forward drive jet outlets 146. The pressurizedflow from the jet outlets 146 creates high velocity gas jets thatgenerate suction that causes a forward flow FF of high pressure, highvelocity air to be drawn outwardly through the dispensing channel 116(FIG. 9). Tablets T are oriented into a preferred orientation by theshape of the inlet 116A to the dispensing channel 116 and dispensed intothe container C through the dispensing channel 116 and the outlet 116Bunder the force of the forward flow FF. The counting sensors 115 countthe tablets T as they pass through a predetermined point in thedispensing channel 116.

The opening of the valve 142 also simultaneously permits the pressurizedsupply gas from the gas source 136 to flow through the passage 140E,through the front air amplifier 150 and out through the front agitationoutlet 122C as an air flow FAF having a relatively low velocity and highmass flow rate as compared to the gas flow from the jet outlets 146(FIG. 9). The air flow FAF flows through and lofts or otherwisedisplaces (i.e., agitates) the tablets T in the front subchamber 120Aproximate the inlet 116A. This agitation of the tablets T helps toorient the tablets T for singulated entry into the dispensing channel116 and to prevent tablet jams. According to some embodiments, theforward jet gas flows and the agitation flow FAF are providedsimultaneously.

Once dispensing is complete (i.e., a predetermined number of tablets hasbeen dispensed and counted), the controller 42 activates the forwardvalve 142 to close and the reverse valve 144 to open. The opened valve144 permits the pressurized gas from the gas source 136 to flow throughthe passage 140D and out through the reverse drive jet outlet 148. Thepressurized flow from the jet outlet 148 creates a high velocity gas jetthat generates suction that causes a reverse (i.e., rearward) flow FR ofhigh pressure air to be drawn inwardly through the dispensing channel116 toward the chamber 120. In this manner, the airflow is reversed andany tablets T remaining in the channel 116 are returned to the chamber120 under the force of the reverse flow (FIG. 10).

The opening of the valve 144 also simultaneously permits the pressurizedsupply gas from the gas source 136 to flow through the passage 140F,through the rear air amplifier 160 and out through the rear agitationoutlet 122D as the air flow FAR which has a relatively low velocity andhigh mass flow rate as compared to the gas flow from the jet outlet 148(FIG. 10). The air flow FAR flows through and lofts or otherwisedisplaces (i.e., agitates) the tablets T in the front subchamber 120Aand/or the intermediate subchamber 120B proximate the choke point 124A.This agitation of the tablets T helps to loosen the tablets T to permitreturn of the tablets T and to prevent or break tablet jams. Accordingto some embodiments, the reverse jet gas flow and the agitation flow FARare provided simultaneously. According to some embodiments, the reversevalve 144 is opened and then closed after a relatively short period toprovide the reverse flow FR and the agitation flow FAR as short bursts.

During a dispensing cycle, the controller 42 may determine that a tabletjam condition is or may be present. Tablets may form a jam at the nozzleinlet 116A, the choke point 124A or the choke point 126A, so that notablets are sensed passing through the dispensing passage 116 for aprescribed period of time while the forward air flow FF is beinggenerated. In this case, the controller 42 will issue a “backjet” byclosing the forward valve 142 and opening the reverse valve 144 asdescribed above for generating the air flows FR, FAR. The air flows FR,FAR may serve to dislodge any jams at the inlet 116A, the choke point124A, or the choke point 126A as well as to loosen the tablets in thesubchamber 120C.

According to some embodiments and as illustrated, the drive jet outlets146 and the agitation outlet 122C (and/or the drive jet outlet 148 andthe agitation outlet 122D) are fluidly connected to the pressurized gassource via the same intake (i.e., the nozzle 134). According to someembodiments and as illustrated, only a single gas source 136 is used tosupply both the drive jet outlets 146 and the agitation outlet 122C orboth the drive jet outlet 148 and the agitation outlet 122D. Accordingto some embodiments, a single gas source is used to supply all drive jetoutlets and agitation outlets.

According to some embodiments, the pressure of the gas supplied to thefeed inlet 152D of each air amplifier 150, 160 is substantially the sameas the pressure of the gas supplied to each drive jet outlet 146, 148.

In the foregoing manner, agitation air flows FAF, FAR can be provided tofacilitate effective and reliable dispensation and return of the tabletsT. The air amplifiers 150, 160 may enable effective agitation of tabletsin the hopper 120 using a supplied gas flow that would otherwise beinsufficient. For example, a compressor having a lower mass flow ratesupply capacity may be used for the gas source 136. This may beparticularly beneficial where a smaller or quieter compressor may beneeded or desired (e.g., in a pharmacy).

Because the air flows FAF, FAR are supplied from a high pressure sourcesuitable to supply the drive jet outlets 146, 148, it is not necessaryto provide a separate low pressure, high mass flow rate air supply toperform tablet agitation and, therefore, the associated apparatus (e.g.,manifolds, pumps, etc.) can be omitted. Moreover, because the air flowsFAF, FAR are supplied from a common (i.e., the same) high pressure gassource 136 as the jets 144, 146, the number of supplies and connectionsrequired can be reduced or minimized. As a result, dispensing systemsand bins according to embodiments of the present invention may be lessexpensive and complicated to manufacture and operate.

The divider walls 124, 126 and choke points 124A, 126A may furtherfacilitate smooth and reliable operation of the bin 100, while alsoallowing for filling the bin 100 with a greater number of tablets. Withreference to FIG. 8, the choke points 124A, 126A limit or reduce theweight load that tends to push the tablets forward into the front orstaging region 120A. As a result, fewer tablets T tend to collect in theregion 120A so that fewer tablets T must be displaced by the air flowFAF from the air amplifier 150. Thus, by reducing the tablet load, thebin 100 may be able to effectively agitate the tablets and prevent jamswith lower air flow energy from the air amplifier 150. The sizes of thechoke points 124A, 126A may be selectively adjusted by raising andlowering the divider walls 124, 126 to customize the bin 100 fordispensing tablets of different sizes, for example.

The angled orientation of the divider wall 126 with respect to verticalalso serves to reduce the forward loading on the tablets T. The angleddivider wall 126 may thereby permit a larger amount of tablets to bestored in the hopper chamber 120.

The arrangement of the divider walls 124, 126 may also serve to promotedispensing of the oldest tablets (i.e., the tablets that have been inthe hopper chamber 120 longest) first. Generally, newer tablets areadded on top of older tablets in the subchamber 120C. Once thebottommost tablets pass through the choke point 126A, they tend not toreturn to the subchamber 120C even when a backjet is executed.

The air amplifiers 150, 160 can be tuned or adjusted to provide thedesired performance in view of other operating parameters (e.g., tabletsize, supplied gas flow rate, etc.). One method in accordance with thepresent invention for adjusting an air amplifier 150, 160 is to replacethe shim 153 with a shim that is thicker or thinner, depending on thedesired adjustment. The described methods of assembly and adjustment mayallow for a relatively low profile air amplifier.

While the bin 100 has been illustrated and described herein with onlyone front air amplifier 150 and one rear air amplifier 160, fewer orgreater numbers of front and rear air amplifiers may be provided. Forexample, there may be two or more front air amplifiers 150 and/or two ormore rear air amplifiers 160. According to some embodiments, the bin mayinclude only a front air amplifier or air amplifiers 150 or,alternatively, only one or more rear air amplifiers 160. The airamplifiers may be arranged and configured in any suitable manner. Forexample, a row or rows of air amplifiers may extend across the width ofthe floor 122.

While the bin 100 has been illustrated and described herein with the airamplifier 150 being supplied from the same valve 142 and controlled ingroup fashion with the drive jet outlets 146 and the air amplifier 160being supplied from the same valve 144 and controlled in group fashionwith the drive jet outlet 148, one or both of the air amplifiers 150,160 can be separately controlled from the associated jet outlets. Forexample, a further valve may be provided that controls the gas supply tothe air amplifier 150 independently of the jet outlets 146, whereby thetablets T may be agitated via the air amplifier 150 prior to providingthe dispensing draw via the jet outlets 146.

According to some embodiments, the agitation outlets 122C, 122D are eachsized and shaped such that tablets of the size and shape intended to bedispensed using the bin cannot fall through the outlet 122C, 122D.According to some embodiments and as illustrated, one or both of theagitation outlets 122C, 122D is an elongated slot. Such a shape mayserve to prevent a tablet from settling over so much of the area of theoutlet 122C, 122D that the Coanda effect is defeated. According to someembodiments, each elongated outlet 122C, 122D has a width of no morethan about 2 mm. According to some embodiments, each elongated outlet122C, 122D has an area of at least about 0.24 in².

While, in the foregoing description, the valves 142, 144 are controlledby the controller 42, the valves 142, 144 may alternatively becontrolled by a local controller unique to each bin 100.

The foregoing is illustrative of the present invention and is not to beconstrued as limiting thereof. Although a few exemplary embodiments ofthis invention have been described, those skilled in the art willreadily appreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention. Accordingly, all such modifications areintended to be included within the scope of this invention. Therefore,it is to be understood that the foregoing is illustrative of the presentinvention and is not to be construed as limited to the specificembodiments disclosed, and that modifications to the disclosedembodiments, as well as other embodiments, are intended to be includedwithin the scope of the invention.

1. An apparatus for dispensing pharmaceutical articles, the apparatuscomprising: a) a housing defining: a hopper chamber to hold thearticles; a dispensing channel fluidly connected to the hopper chamber,the dispensing channel having an inlet and an outlet and defining a flowpath therebetween; a drive jet outlet; and an agitation outlet; and b) agas source to provide a positive pressure supply gas flow, wherein thegas source is fluidly connected to each of the drive jet outlet and theagitation outlet to provide: a pressurized drive jet gas flow throughthe drive jet outlet to convey articles through the dispensing channelalong the flow path; and a pressurized agitation gas flow through theagitation outlet to agitate articles in the hopper chamber; wherein theapparatus is configured to generate the drive jet gas flow and theagitation gas flow simultaneously using the same gas source.
 2. Theapparatus of claim 1 including an air amplifier interposed and fluidlyconnected between the gas source and the agitation outlet, and whereinthe agitation gas flow has a greater mass flow rate than the supply gasflow.
 3. The apparatus of claim 1 wherein: the housing further includesa second agitation outlet; and the gas source is fluidly connected tothe second agitation outlet to provide a second pressurized agitationgas flow through the second agitation outlet to agitate articles in thehopper chamber.
 4. The apparatus of claim 3 wherein: the housingincludes a divider wall configured to define, in the hopper chamber, afront region between the inlet and the divider wall and a rear region ona side of the divider wall opposite the front region, and to furtherform a choke passage between the front and rear regions; the agitationoutlet is a first agitation outlet and the agitation gas flow is a firstagitation gas flow; the first agitation outlet is positioned andconfigured to direct the first agitation gas flow into the front regionto agitate articles in the front region; and the second agitation outletis positioned and configured to direct the second agitation gas flowinto the rear region to agitate articles in the rear region; the housingis configured to direct tablets through the choke passage from the rearregion to the front region.
 5. The apparatus of claim 4 wherein: thedrive jet gas flow is operative to convey the articles through thedispensing channel in a forward direction toward the outlet; and theapparatus includes at least one valve operable to simultaneously providethe drive jet gas flow through the drive jet outlet and the firstagitation gas flow through the first agitation outlet to dispensearticles from the hopper chamber.
 6. The apparatus of claim 4 wherein:the drive jet gas flow is operative to convey the articles through thedispensing channel in a reverse direction toward the inlet; and theapparatus includes at least one valve operable to simultaneously providethe drive jet gas flow through the drive jet outlet and the secondagitation gas flow through the second agitation outlet.
 7. The apparatusof claim 4 wherein the housing further includes a second divider wallconfigured to divide the rear region into a first rear region betweenthe first and second divider walls and a second rear region on a side ofthe second divider wall opposite the first rear region, the seconddivider wall forming a second choke passage between the first and secondrear regions, wherein the housing is configured to direct tabletsthrough the second choke passage from the second rear region to thefirst rear region and thereafter from the first rear region to the frontregion.
 8. The apparatus of claim 4 wherein a spacing between thedivider wall and a floor of the housing is adjustable to adjust the sizeof the choke passage.
 9. The apparatus of claim 1 wherein: the drive jetgas flow is operative to convey the articles through the dispensingchannel in a reverse direction toward the inlet; and the apparatusincludes a controller operative to simultaneously provide the drive jetgas flow through the drive jet outlet and the agitation gas flow throughthe agitation outlet responsive to a tablet jam condition.
 10. A methodfor dispensing pharmaceutical articles, the method comprising: a)providing an apparatus including: 1) a housing defining: a hopperchamber to hold the articles; a dispensing channel fluidly connected tothe hopper chamber, the dispensing channel having an inlet and an outletand defining a flow path therebetween; a drive jet outlet; and anagitation outlet; and 2) a gas source to provide a positive pressuresupply gas flow, wherein the gas source is fluidly connected to each ofthe drive jet outlet and the agitation outlet; and b) providing thepositive pressure supply gas flow from the gas source to each of thedrive jet outlet and the agitation outlet to simultaneously generate,using the same gas source, each of a pressurized drive jet gas flowthrough the drive jet outlet and a pressurized agitation gas flowthrough the agitation outlet, wherein the drive jet gas flow conveysarticles through the dispensing channel along the flow path and theagitation gas flow agitates articles in the hopper chamber.
 11. Themethod of claim 10 wherein the agitation gas flow has a greater massflow rate than the supply gas flow.
 12. The method of claim 10 furtherincluding providing the positive pressure gas from the gas source to asecond agitation outlet in the housing to generate a second pressurizedagitation gas flow through the second agitation outlet to agitatearticles in the hopper chamber.
 13. The method of claim 12 wherein theagitation gas flow is a first agitation gas flow, the method including:providing a divider wall configured to define, in the hopper chamber, afront region between the inlet and the divider wall and a rear region ona side of the divider wall opposite the first region, and to furtherform a choke passage between the front and rear regions; directing thefirst agitation gas flow into a front region to agitate articles in thefront region; and directing the second agitation gas flow into the rearregion to agitate articles in the rear region.
 14. The method of claim13 including: conveying the articles through the dispensing channel in aforward direction toward the outlet using the drive jet gas flow; andproviding the drive jet gas flow through the drive jet outlet and thefirst agitation gas flow through the first agitation outletsimultaneously to dispense articles from the hopper chamber.
 15. Themethod of claim 13 including: conveying the articles through thedispensing channel in a reverse direction toward the inlet using thedrive jet gas flow; and providing the drive jet gas flow through thedrive jet outlet and the second agitation gas flow through the secondagitation outlet simultaneously.
 16. The method of claim 10 including:detecting a tablet jam condition; and in response to the tablet jamcondition, generating the drive jet gas flow and the agitation gas flow,wherein the drive jet gas flow is operative to convey the articlesthrough the dispensing channel in a reverse direction toward the inlet.17. The method of claim 10 wherein: the housing includes a divider wallconfigured to define, in the hopper chamber, a front region between theinlet and the divider wall and a rear region on a side of the dividerwall opposite the front region, and to further form a choke passagebetween the front and rear regions; the housing further includes asecond agitation outlet and the gas source is fluidly connected to thesecond agitation outlet to provide a second pressurized agitation gasflow through the second agitation outlet to agitate articles in thehopper chamber; the drive jet outlet is a forward drive jet outlet andthe drive jet gas flow is a forward drive jet gas flow; the housingfurther includes a reverse drive jet outlet and the gas source isfluidly connected to the reverse drive jet outlet to provide a reversedrive jet gas flow through the reverse drive jet outlet to conveyarticles through the dispensing channel along the flow path; theagitation outlet is a first agitation outlet and the agitation gas flowis a first agitation gas flow; the first agitation outlet is positionedand configured to direct the first agitation gas flow into the frontregion to agitate articles in the front region; the second agitationoutlet is positioned and configured to direct the second agitation gasflow into the rear region to agitate articles in the rear region; theforward drive jet gas flow is operative to convey the articles throughthe dispensing channel in a forward direction toward the outlet; thereverse drive jet gas flow is operative to convey the articles throughthe dispensing channel in a reverse direction toward the inlet; and themethod includes alternating between a forward mode and a reverse mode,wherein: in the forward mode, the apparatus simultaneously provides theforward drive jet gas flow through the forward drive jet outlet and thefirst agitation gas flow through the first agitation outlet to dispensearticles from the hopper chamber while not providing the reverse drivejet gas flow and the second agitation gas flow; and in the reverse mode,the apparatus simultaneously provides the reverse drive jet gas flowthrough the reverse drive jet outlet and the second agitation gas flowthrough the second agitation outlet to return articles to the hopperchamber while not providing the forward drive jet gas flow and the firstagitation gas flow.
 18. An apparatus for dispensing pharmaceuticalarticles, the apparatus comprising: a dispensing channel having an inletand an outlet and defining a flow path therebetween; a housing defininga hopper chamber to hold the articles, wherein the hopper chamber is influid communication with the inlet of the dispensing channel, thehousing including a floor and a divider wall configured to define, inthe hopper chamber: a front region between the inlet and the dividerwall; a rear region on a side of the divider wall opposite the frontregion; and a choke passage between the front and rear regions andbetween the divider wall and the floor; wherein a spacing between thedivider wall and the floor is adjustable to adjust the size of the chokepassage.
 19. The apparatus of claim 18 wherein the housing furtherincludes a second divider wall configured to divide the rear region intoa first rear region between the first and second divider walls and asecond rear region on a side of the second divider wall opposite thefirst rear region, the second divider wall forming a second chokepassage between the first and second rear regions and between the seconddivider wall and the floor, wherein the housing is configured to directtablets through the second choke passage from the second rear region tothe first rear region and thereafter from the first rear region to thefront region.
 20. The apparatus of claim 18 including an agitationoutlet in the housing and a gas source fluidly connected to theagitation outlet, wherein the agitation outlet is positioned andconfigured to direct a gas flow from the gas source into at least one ofthe front region and the rear region to agitate articles therein. 21.The apparatus of claim 18 wherein the divider wall is angled withrespect to vertical to support a load of the articles in the rearregion.